JPH10102394A - Production of composite formed product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a production process which can readily produce formed composite products having resistance to fire and electromagnetic wave-shielding properties, in a uniform thickness and in a high productivity. SOLUTION: A self-curing particle slurry 2 is prepared by dispersing self- curing particles comprising powdery particles having fire resistance and electroconductivity and a self-curing thermosetting resin. This self-curing particle slurry 2 is subjected to sheet making to prepare the objective self-curing sheet. This self-curing sheet 5 is thermocompressed into a composite molded product.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a composite material with a fire resistant and conductive powder resin.

[0002]

2. Description of the Related Art Carbon materials such as graphite and metallic materials such as copper have high fire resistance and conductivity. Therefore, by using these materials, it is possible to manufacture a product having not only excellent fire resistance but also electromagnetic shielding properties based on its conductivity. Then, using the powder of the material having the fire resistance and the electrical conductivity, a self-curing particle is prepared by mixing the powder and the particle with a self-curing thermosetting resin, and the self-curing particle is formed. The production of a product having fire resistance and electromagnetic wave shielding properties by this has been provided by the present applicant in Japanese Patent Application Laid-Open No. 2-261855 and the like. The self-curing particles obtained by mixing such a powder and a resin can be formed into a plate or any other form by being poured into a mold and molded. By spraying self-curing particles on the material and molding it under heat and pressure, it is possible to laminate layers with fire resistance and electromagnetic wave shielding properties on the base material, making it easy to develop into various products It is.

[0003]

However, as described above, when the self-curing particles are put into a mold and molded, or when the self-curing particles are sprayed and molded on a substrate, the molding is carried out. It takes time to weigh and supply the self-curing particles, or it takes time to weigh the self-curing particles on the base material and spread it evenly, which has a problem in productivity. Was something. When molding the self-curing particles as they are,
There is also a problem that it is difficult to form a thin film having a uniform thickness or to laminate the film on a substrate with a uniform thickness.

[0004] The present invention has been made in view of the above points, and provides a method of manufacturing a composite molded article having high fire resistance and electromagnetic wave shielding properties, which is highly productive and can be easily formed with a uniform thickness. It is intended to do so.

[0005]

SUMMARY OF THE INVENTION According to the present invention, there is provided a method of manufacturing a composite molded article, comprising a step of dispersing self-curing particles comprising a fire-resistant and conductive powder and a self-curing thermosetting resin. Preparing a curable particle slurry, producing a self-curable sheet in which self-curable particles are aggregated by forming the self-curable particle slurry, and subjecting the self-curable sheet to heat and pressure molding. It is.

[0006] The invention of claim 2 is characterized in that, as the self-curing particles, those obtained by mixing and reacting a resin raw material with a powder having fire resistance and conductivity are used. is there. The invention of claim 3 is:
The present invention is characterized in that a self-curing particle slurry prepared by dispersing self-curing particles and fibers is used.

The invention of claim 4 is characterized in that a self-curing particle slurry prepared by dispersing self-curing particles and a binder is used. The invention according to claim 5 is characterized in that a self-curing particle slurry prepared by dispersing self-curing particles, fibers and a binder is used. The invention according to claim 6 is characterized in that a self-curing sheet is produced by filtering the self-curing particle slurry on the surface of a papermaking drum and transferring the slurry onto the surface of an infinite belt-like papermaking felt. Things.

[0008] The invention of claim 7 is characterized in that the self-curing sheet is laminated on another base material and is subjected to heat and pressure molding. The invention of claim 8 is characterized in that a secondary binder is penetrated into the self-curable sheet. Further, the invention of claim 9 is to form a fiber layer by forming a fiber slurry on the surface of the infinite belt-shaped papermaking felt, and by laminating a laminated layer obtained by forming a self-curing particle slurry on the surface of the fiber layer, The present invention is characterized in that a self-curing sheet comprising a fiber layer and a laminated layer of self-curing particles is produced.

[0009] The invention according to claim 10 is to provide a reinforcing sheet by laminating a reinforcing sheet on the surface of an infinite strip-shaped papermaking felt and laminating a laminated layer of self-curing particle slurry on the surface of the reinforcing sheet. And a self-curable sheet comprising a laminated layer of self-curable particles. Further, the invention according to claim 11 is that, by laminating a laminated layer obtained by forming a self-curable particle slurry on the surface of a reinforcing sheet, and laminating and laminating a reinforcing sheet on the surface of the laminated layer, two reinforcing sheets are used. The present invention is characterized in that a self-curable sheet in which a laminated layer of self-curable particles is sandwiched is produced.

[0010]

Embodiments of the present invention will be described below. In the present invention, as the powder having fire resistance and conductivity, although not particularly limited, powder of carbon material, powder of metal material, powder of other inorganic material may be used. it can.

As the above-mentioned carbon material, for example, natural graphite, artificial graphite, exfoliated graphite, graphite intercalation compound, carbon black, coke powder, charcoal powder, carbon fiber and the like can be used. Seeds can be used in combination. The particle size of the carbon material powder is not particularly limited, but the average particle size is 0.1 μm.
Those having a size of about m to 200 μm are preferred.

The above-mentioned powdery metal material includes:
Illustrate silver, copper, gold, chromium, aluminum, brass, magnesium, tungsten, zinc, cadmium, nickel, phosphor bronze, tin, beryllium, lead, iron, steel, silicon iron, permalloy, mypanic, superalloy In addition, oxides such as ferrite and other metal compounds such as barium titanate can also be used.
In the present invention, among these, the volume resistivity is 10 ⁸ Ω · c.
Metals of m or less are preferred, and ferrite, which is an oxide of iron, is particularly preferred because it exhibits ferromagnetism. The lower the volume resistivity is, the smaller the better.
Practically, the lower limit is about 10 ⁻⁶ Ω · cm. The particle size of the metal material powder is not particularly limited, but preferably has an average particle size of about 1 μm to 50 μm.

In the present invention, the self-curing particles are those comprising the above-mentioned fire-resistant and conductive powder and a self-curing thermosetting resin. The curable resin is not particularly limited, but a phenol resin, a melamine resin, a furan resin, or the like can be used. Here, the self-curing thermosetting resin is a resin in a semi-cured state that has not yet been completely cured, and once melted by heating,
It refers to one in which curing progresses and is completely cured.

[0014] Such self-curing particles include:
It is desirable to use a resin prepared by mixing and reacting the resin raw material of the thermosetting resin with the above-mentioned powder and granules having fire resistance and conductivity. To explain the case of using a phenol resin as the thermosetting resin, using phenols and formaldehyde as resin raw materials,
By reacting the phenols and formaldehydes while mixing with the above-mentioned powder in the presence of a catalyst, self-curing particles composed of a particulate material in which a powder and a phenol resin initial condensate are composited are prepared. Is what you can do.

Here, the above-mentioned phenols mean phenol and phenol derivatives, for example, m-cresol, resorcinol,
Trifunctional ones such as 3,5-xylenol, tetrafunctional ones such as bisphenol A and dihydroxydiphenylmethane, o-cresol, p-cresol, p-te
Bifunctional o- or p-substituted phenols such as r-butylphenol, p-phenylphenol, p-cumylphenol, p-nonylphenol, 2,4 or 2,6-xylenol, and the like. Halogenated phenols substituted with chlorine or bromine can also be used. Of course, one of these can be selected and used, or a plurality of types can be mixed and used. As the above-mentioned formaldehyde, formalin which is in the form of an aqueous solution is optimal, but those in the form of paraformaldehyde, trioxane and tetraoxane can also be used, and in addition, a part or most of formaldehyde can be furfural or furfuryl. It is also possible to use in place of alcohol.

The mixing ratio of phenols and formaldehyde is preferably set so that the molar ratio of phenols to formaldehyde is in the range of 1: 1 to 1: 3.5. Further, as a reaction catalyst, a basic substance that generates a> NCH ₂ -bond between benzene nuclei of phenols, for example, hexamethylenetetramine, ammonia and methylamine, dimethylamine, ethylenediamine, monoethanolamine And primary and secondary amines. Further, in combination with these, a basic catalyst generally used when synthesizing a phenol resin such as an alkali metal or alkaline earth metal hydroxide or a tertiary amine can be used.

The phenol, formaldehyde and the reaction catalyst are charged into a reaction vessel such as a reaction vessel, and the phenol and formaldehyde are reacted.
At this time, the above-mentioned powder and granules were further added to the reaction vessel, and a reaction between phenols and formaldehyde was carried out in the presence of the powder and the powder, whereby the initial condensate of the powder and the phenol resin was combined. As the granular material, the self-curing particles used in the present invention can be prepared.

Here, when the phenol and the formaldehyde are reacted as described above in the presence of the granular material, this reaction is carried out in the presence of at least an amount of water sufficient to stir the reaction system. is there. When phenols and formaldehydes are reacted in the presence of powder and granules while stirring in water in this way, at the beginning of the reaction, the reaction system is in a viscous mayonnaise state and flows with stirring, As the reaction progresses, the condensation reaction product of the phenols and formaldehyde containing the particulates gradually begins to separate from the water in the system, and the particles formed of the phenolic resin and the particulates that are produced by the reaction suddenly fall into the reaction vessel. Will be distributed throughout.

After the mixed particles of the powder and the phenol resin are dispersed and generated as described above, when the reaction of the phenol resin is further advanced to a desired degree and the stirring is stopped after cooling, the particles are precipitated. Separated from water. These particles are minute spherical granules, which can be easily separated by taking out from the reaction vessel and filtering. Curable particles can be obtained. Although the particle size of the self-curable particles is not particularly limited, it is generally desirable to adjust the particle size to a range of about 10 μm to 2000 μm.

Next, the case where a melamine resin is used as the thermosetting resin will be described. In the case of a melamine resin, melamines and formaldehydes are used as resin raw materials, and the melamines and the formaldehydes are reacted while being mixed with the above-mentioned powder and granules in the presence of a catalyst, whereby the case of the phenol resin is used. In the same manner, self-curing particles composed of a powder and a precondensate of a melamine resin can be prepared. Melamines and derivatives thereof can be used as melamines, and those described above can be used as formaldehydes. Acids or alkalis can be used as the catalyst.

Next, the case where a furan resin is used as the thermosetting resin will be described. In the case of furan resins, furans and formaldehydes are used as resin raw materials,
By reacting the furans and formaldehyde with the above-mentioned powder and granules in the presence of a catalyst,
Self-curing particles composed of a powder and a furan resin can be prepared. Furans such as furfuryl alcohol and furfural can be used as the furans, and acids and the like can be used as the catalyst. In the case of this furan resin, it is generally difficult to prepare spherical granules like the above-mentioned phenol resin and melamine resin.

In the present invention, the self-curable particles obtained as described above are dispersed in water to prepare a self-curable particle slurry,
This self-curing particle slurry is formed into a self-curing sheet in which self-curing particles are assembled. As the self-curing slurry, it is preferable to use a slurry in which self-curing particles are dispersed in water at a concentration of about 0.1 to 30% by weight. In preparing a self-curable sheet by forming a self-curable slurry, it can be performed by a method as shown in FIG.

That is, in FIG. 1, 1 is a papermaking vat to which a self-curing particle slurry 2 is supplied, 3 is a papermaking drum formed by a circular mesh which is driven by rotating a lower portion by being immersed in the self-curing particle slurry 2, Reference numeral 4 denotes an infinite belt-shaped papermaking felt. The papermaking felt 4 is brought into contact with the outer periphery of the papermaking drum 3 by a felt driving roll 17 so as to be driven at the same speed as the rotation speed of the papermaking drum 3. . When the papermaking drum 3 is driven to rotate, the water in the self-curing particle slurry 2 in the papermaking vat 1 is filtered from the outer periphery of the papermaking drum 3 inward, and the self-curing particle slurry 2 in the self-curing particle slurry 2 is filtered. The curable particles remain on the outer periphery of the paper making drum 3 and are made. The laminated layer 7 of the self-curable particles formed on the outer periphery of the papermaking drum 3 is transferred from the outer periphery of the papermaking drum 3 to the surface of the papermaking felt 4 as shown in FIG. The laminated layer 7 of the conductive particles can be adhered in a long sheet shape. After squeezing the water through a squeeze roll 9, the aggregate layer 7 of the self-curing particles adhering to the surface of the papermaking felt 4 is removed.
The self-curable sheet 5 in which the self-curable particles are aggregated can be obtained by peeling off the self-curable particles.

In forming the self-curing sheet 5 by forming the self-curing particle slurry 2 as described above, the self-curing particle slurry 2 in which the self-curing particles are merely dispersed in water is used.
In the case of using, since the self-curable particles cannot be strongly bonded to each other, it is difficult to produce the self-curable sheet 5 having a strength that can be used. Therefore,
In order to bond the self-curable particles to each other, it is preferable to use a self-curable particle slurry 2 prepared by dispersing fibers or a binder in addition to the self-curable particles in water. Needless to say, the fiber and the binder may be used in combination.

When the paper is formed by blending the fibers with the self-curable particle slurry 2, the self-curable particles are bound by the entanglement of the fibers, so that a high-strength self-curable sheet 5 can be produced. It becomes possible. As this fiber, an inorganic fiber or an organic fiber can be used. As the inorganic fibers, E-glass, S-glass, glass fibers such as quartz fibers, ceramic fibers, alumina fibers,
Zirconia fibers, whiskers, carbon fibers, or composite fibers obtained by compounding them, or metal fibers such as tungsten, molybdenum, steel, and stainless steel can be used. Organic fibers include vegetable fibers such as cotton, flax, hemp, softwood pulp, hardwood pulp, straw pulp, waste paper pulp, animal fibers such as wool and silk, recycled fibers such as rayon, vinylon, polypropylene, polyamide, and acrylic. And synthetic fibers such as polyester. These fibers preferably have a fiber length of about 0.01 to 5 mm.

The binder is used as a self-curing particle slurry 2
When self-curing particles are mixed together by self-curing, the self-curing particles are bonded by an adhesive action of a binder, so that a high-strength self-curing sheet 5 can be produced. Examples of the binder include acrylic polymers, polyvinyl alcohol, polyvinyl butyral, polyethylene oxide, resin binders such as phenolic resins, methyl cellulose, carboxymethyl cellulose, ethyl cellulose, hydroxypropyl cellulose, gum arabic, α starch, β starch, guar gum, etc. Further, "Isoban" manufactured by Kuraray Co., Ltd., and "Silyl" and "Kanekazemurak" manufactured by Kanekachi Chemical Industry Co., Ltd. can also be used as commercially available products.

When the fibers are mixed into the self-curing particle slurry 2 as described above, the amount of the fibers is 100%.
It is preferable to set the range of 0.3 to 15 parts by weight with respect to parts by weight. When the binder is blended in the self-curing particle slurry 2, the amount of the binder is adjusted to be equal to the self-curing particle 10 or less.
It is preferably set in the range of 0.1 to 10 weight (solid content) based on 0 weight part. When the fiber and the binder are used in combination, it goes without saying that the blending amount of the fiber and the binder may be smaller than these.

The self-curing sheet 5 obtained by forming the self-curing particle slurry 2 as described above is manufactured by the same method as that for forming paper or the like. A self-curable sheet 5 having a uniform thickness can be produced, and the self-curable sheet 5 can be produced with high productivity as a continuous long sheet by continuous operation of the papermaking drum 3 and the papermaking felt 4. After drying, the self-curable sheet 5 manufactured in a long length can be wound up in a roll shape and stocked. here,
Although the thickness of the self-curable sheet 5 can be arbitrarily formed, it is preferable that the self-curable sheet 5 is formed in a range of about 0.05 to 2.0 mm.

Then, the self-curing sheet 5 thus produced is cut into a predetermined size, and a single sheet or a plurality of these sheets are stacked and heated and pressed to form a self-curing sheet 5 in the self-curing sheet 5. Melting and curing the curable thermosetting resin,
It is capable of molding a composite molded article having fire resistance and electromagnetic wave shielding properties. As described above, the self-curable sheet 5 can be manufactured with a thin and uniform thickness, so that it is possible to manufacture a thin and uniform composite molded article. By laminating and laminating a plurality of sheets 5, it is also possible to produce a composite molded article having an arbitrary thickness. Also, in addition to manufacturing a composite molded body by molding into a plate shape, the self-curing sheet 5 is set in a three-dimensional molding die and subjected to heat and pressure molding, thereby forming a three-dimensional molding such as a casing of an electric appliance. It can also be formed into a product.

Further, in addition to forming the self-curable sheet 5 alone, one or more self-curable sheets 5 are superimposed on the surface of the base material 6 and are formed by heating and pressing.
As shown in FIG. 2, the self-curable sheet 5 is formed into a composite molded body A, and the composite molded body A is laminated on the base material 6 by the self-adhesive property of the self-curable thermosetting resin in the self-curable sheet 5. A composite material can be manufactured. As the substrate 6, a wood plate such as plywood or a particle board, a metal or ceramic plate, or the like can be used. It can be used as a building material having excellent electromagnetic wave shielding properties.

In the composite molded article obtained by molding the self-curing sheet as described above, since the composite molded article contains the powdery material having fire resistance and conductivity, The composite molded body has high fire resistance and electromagnetic wave shielding properties due to the action of this powder and granule, but in particular, as a self-curing particle, a resin material of a thermosetting resin is used as a powder and a particle having fire resistance and conductivity. By using a material prepared by reacting while mixing, higher electromagnetic wave shielding properties can be exhibited. In other words, in the present invention, as the self-curing particles, it is also possible to use a material prepared by kneading a thermosetting resin such as a phenol resin with a kneader or the like to a powder having fire resistance and conductivity, and crushing the kneaded resin. However, a self-curable sheet is formed using the self-curable particles prepared in this manner, and a composite molded body manufactured by molding the self-curable sheet is a low-frequency electromagnetic wave of 400 to 500 MHz or less. Also, the effect of shielding electromagnetic waves having a high frequency of 600 to 700 MHz or more is not sufficient. On the other hand, in the case of a composite molded article prepared by reacting a resin material of a thermosetting resin as a self-curing particle while mixing and reacting with a powdery material having fire resistance and conductivity, these frequencies are used. Thus, a high electromagnetic wave shielding effect can be obtained. The reason is not clear, but when the powder and the resin are mixed and used in a kneader or the like, the powder and the powder can be uniformly dispersed due to poor wettability between the powder and the resin. However, it is considered that an agglomerate consisting only of powder and granules and an agglomerate consisting only of resin are formed, and as a result, leakage of electromagnetic waves from the resin portion, which is an electrical insulator, increases, leading to a decrease in the electromagnetic wave shielding effect. On the other hand, when the resin material is allowed to react in the presence of a catalyst, if the powder and the granules are mixed, the powder and the granules are uniformly dispersed in the resin, which is caused by the uniformity of the dispersion of the powder and the granules. It is considered that the electromagnetic wave shielding effect is high.

The composite molded article according to the present invention has a density of 0.5 g / c in order to obtain a sufficient electromagnetic wave shielding property.
m ³ , preferably 1 g / cm ³ or more. If the density is less than 0.5 g / cm ^3, the effect of shielding electromagnetic waves in a high frequency range is reduced. If the content of the powder having fire resistance and conductivity is small, the electromagnetic wave shielding effect cannot be sufficiently obtained, so that the content of the powder in the composite molded article is 2% by weight.
It is preferable to set as described above. The higher the content of the granular material, the higher the electromagnetic wave shielding effect, but if the content is too high, the strength of the composite molded body decreases,
It is preferable to set the upper limit of the content of the powder to about 95% by weight.

Next, another method for producing a self-curing sheet is shown in FIG.
It will be described based on. The self-curing particle slurry 2 is formed on the paper-making drum 3 and the laminated layer 7 of self-curing particles formed on the outer periphery of the paper-making drum 3 is formed into an infinite strip-shaped felt 4.
The process up to the transfer to the surface of FIG.
After the layer 7 of self-curing particles is transferred to the surface of the papermaking felt 4 in this manner, the layered body 7 is passed through the squeeze roll 9 together with the papermaking felt 4 to squeeze out moisture and dewater. Next, the secondary binder 8 is infiltrated into the dehydrated laminated layer 7. The penetration of the secondary binder 8 is, for example, as shown in FIG.
As shown by the arrow in (b), the solution can be carried out by spraying the solution of the secondary binder 8 onto the laminated layer 7 from above. Then, the secondary binder 8 is added to the laminated layer 7 in this manner.
Then, the excess secondary binder 8 is squeezed through a squeeze roll 10 to squeeze the aggregated layer 7 into a papermaking felt 4.
The self-curable sheet 5 can be obtained by peeling off and drying. Here, as the secondary binder 8, the same binder as that exemplified as the binder to be blended into the self-curing particle slurry 2 can be used.

By forming the self-curing sheet 5 by infiltrating the secondary binder 8 as described above, the self-curing particles can be bonded by the adhesive action of the secondary binder 8, and the self-curing sheet having high strength can be obtained. The functional sheet 5 can be obtained. Therefore, when the secondary binder 8 is made to penetrate in this way, the self-curing particle slurry 2 in which the self-curing particles are merely dispersed in water, that is, the self-curing particle slurry which does not contain fiber or binder is used. Is possible. Of course, it is needless to say that the self-curing particle slurry 2 may be a mixture of fibers or a binder, or a mixture of both fibers and a binder. When using a self-hardening particle slurry 2 containing no fiber or binder,
The permeation amount of the secondary binder 8 into the assembling layer 7 is 5 to 100 parts by weight of the self-curing particles per unit area of the assembling layer 7.
It is preferable to adjust so as to be 100 parts by weight. In the case of using the self-curing particle slurry 2 in which fibers and a binder are blended, it goes without saying that the amount of the secondary binder 8 permeated may be smaller than this amount.

FIG. 4 shows still another method for producing the self-curing sheet 5. In addition to the papermaking vat 1 for supplying the self-curing particle slurry 2, a fiber slurry prepared by dispersing fibers in water Fiber slurry papermaking vat 1 to which 11 is supplied
2 is provided, and the fiber slurry-making drum 13 whose lower part is immersed in the fiber slurry 11
2 is arranged. The fiber slurry-making drum 13 is driven to rotate at the same speed as the above-mentioned paper-making drum 3, and the felt 4 is brought into contact with the outer periphery of the fiber slurry-making drum 13. Reference numeral 18 denotes a holding roll. And the fiber slurry making drum 13
When the is rotated, the fibers in the fiber slurry 11 are formed on the outer periphery of the fiber slurry forming drum 13, and the fibers are transferred from the outer periphery of the fiber slurry forming drum 13 to the surface of the felt 4 as a fiber layer 14. Here, the fibers of the fiber slurry 11 include the self-curing particle slurry 2.
The same fibers as those exemplified above can be used.

The papermaking felt 4 comes into contact with the outer periphery of the papermaking drum 3 with the fiber layer 14 adhered to the surface as described above. Is transferred from the papermaking drum 3 to the surface of the fiber layer 14 as shown in FIG. After squeezing the water through a squeeze roll 9 and removing the water from the surface of the papermaking felt 4, a self-curing sheet 5 having a two-layer structure of a fiber layer 14 and a self-curing particle assembly 7 can be obtained. It is.

As described above, by forming the self-curable sheet 5 by laminating the self-curable particle aggregate layer 7 on the fiber layer 14, the self-curable sheet 5 having high strength due to the reinforcing effect of the fiber layer 14 is obtained. What you can get. Therefore, when laminating the fiber layers 14 in this manner, it is possible to use the self-curable particle slurry 2 in which the self-curable particles are merely dispersed in water, that is, the self-curable particle slurry 2 in which the fibers and the binder are not blended. It becomes possible. Of course, it is needless to say that the self-curing particle slurry 2 may be a mixture of fibers or a binder, or a mixture of both fibers and a binder. In this manufacturing method, the laminated layer 7 and the fiber layer 14 of the self-curing particles transferred to the surface of the papermaking felt 4 are passed through a squeeze roll 9 to be dehydrated, and then the secondary binder 8 is allowed to penetrate the laminated layer 7. It may be.

FIG. 5 shows still another method for producing the self-curing sheet 5. In this example, a long belt-shaped reinforcing sheet 15 is superposed on the surface of the papermaking felt 4 and a roll 1 is formed.
6, the sheet is fed so as to pass the reinforcing sheet 15 between the papermaking drum 3 and the papermaking felt 4. Therefore, in this case, the laminated layer 7 of the self-curing particles formed on the outer periphery of the papermaking drum 3 is transferred from the papermaking drum 3 to the surface of the reinforcing sheet 15 and laminated as shown in FIG. Then, by peeling off the reinforcing sheet 15 from the surface of the papermaking felt 4, the self-curing sheet 5 having a two-layer structure of the reinforcing sheet 15 and the self-curing particle aggregate layer 7 can be obtained.
If the resin is not impregnated, it is necessary that the melted resin penetrates when the self-curable sheet 5 is formed. Therefore, it is preferable to use a material that can penetrate the resin. For example, paper, glass fiber cloth, natural fiber cloth, synthetic fiber cloth and the like can be used. Further, as the reinforcing sheet 15, a resin-impregnated fiber cloth can be used.

In the example of FIG. 6, the reinforcing sheet 15 is sent over the papermaking felt 4, and the laminated layer 7 of the self-curing particles is laminated on the surface of the reinforcing sheet 15. 15 is supplied at the same speed as the traveling speed of the papermaking felt 4, and is superposed on the laminated layer 7 by the superimposing roll 19 to be laminated. And papermaking felt 4
The self-curing sheet 5 having a three-layer structure in which the self-curing particle assembly 7 is sandwiched between the two reinforcing sheets 15 by peeling the self-curing particle assembly layer 7 and the reinforcing sheet 15 from the surface Can be done.

As described above, by forming the self-curable sheet 5 by laminating the reinforcing sheet 15 and the laminated layer 7 of the self-curable particles, the self-curable sheet 5 having high strength by the reinforcing action of the reinforcing sheet 15 can be obtained. What you can get. Therefore, when the reinforcing sheet 15 is used as described above, it is possible to use the self-curable particle slurry 2 in which the self-curable particles are simply dispersed in water, that is, the self-curable particle slurry 2 in which fibers or binders are not blended. It becomes something. Of course,
Needless to say, the self-curing particle slurry 2 may be a mixture of fibers or a binder, or a mixture of both fibers and a binder.
In this manufacturing method, the secondary binder 8 may be made to permeate the laminate of the reinforcing sheet 15 and the laminated layer 7 of the self-curable particles.

[0041]

Next, the present invention will be described specifically with reference to examples. (Production Example 1 of Self-Curing Particles) The average particle size was 5 μm
1100 parts by weight of flaky graphite and 770 phenol
Parts by weight, 1328 parts by weight of 37% formalin, 80 parts by weight of hexamethylenetetramine as a reaction catalyst, and 80 parts by weight of water. The mixture was stirred and heated to 90 ° C. over 60 minutes while stirring. The reaction was maintained for 3 hours. As a result of this reaction, black granules composed of graphite and a phenol resin were generated in the reaction system. After cooling, the black granules were separated by filtration and dried to obtain self-curing particles composed of graphite and a phenol resin. The self-curing particles have an average particle size of 150
μm, the content of graphite was 60% by weight, and the content of phenolic resin was 40% by weight, which was pulverized to a particle size of 105 μm or less for use.

(Production Example 2 of Self-Curing Particles) In a reaction vessel, 1100 parts by weight of flaky graphite having an average particle diameter of 5 μm, 980 parts by weight of furfree alcohol, 405 parts by weight of 37% formalin, and 500 parts of water were added. 30 parts by weight of a 10% aqueous solution of phosphoric acid as a reaction catalyst were further charged, and the mixture was reacted under reflux for 180 minutes while stirring. After cooling this, water was separated and freeze-dried to obtain a material composed of graphite and furan resin. It had a graphite content of 61.8% by weight and a furan resin content of 38.2.
% By weight and pulverized to a particle size of 105 μm or less to obtain self-curable particles.

(Production Example 3 of Self-Curing Particles) In a reaction vessel, 1100 parts by weight of flaky graphite having an average particle diameter of 5 μm, 750 parts by weight of melamine, 960 parts by weight of 37% formalin,
1150 parts by weight of water and 11 parts of formic acid as a reaction catalyst
0 parts by weight were charged, and the mixture was heated to 70 ° C. over 30 minutes while mixing and stirring, and allowed to react for 240 minutes. As a result of the reaction, black granules composed of graphite and melamine resin were generated in the reaction system.
After cooling, the black granules were separated by filtration and dried to obtain self-curing particles composed of graphite and a melamine resin.
The self-curing particles had a graphite content of 58.5% by weight and a melamine resin content of 41.5% by weight, and were used by being pulverized so that the particle diameter became 105 μm or less.

(Production Example 4 of Self-Curable Particles) In a reaction vessel, flaky graphite having an average particle size of 5 μm was added as conductive filler to 2
50 parts by weight of ferrite powder having an average particle size of 5 μm (Fe
₃ O _4; volume resistivity 10 ⁰ Ω · cm) 50 parts by weight were charged, further 80 parts by weight of phenol, 150 parts by weight of 37% formalin, hexamethylenetetramine with charged 20 parts by weight as a reaction catalyst, the water 200 By weight, the mixture was stirred and heated to 90 ° C. in 60 minutes while maintaining the reaction, and the reaction was maintained for 3 hours. As a result of this reaction, black granules composed of graphite, ferrite and phenol resin were generated in the reaction system. After cooling, the black granules were separated by filtration and dried to obtain self-curing particles composed of graphite, ferrite and a phenol resin. The self-curing particles have an average particle size of 110 μm,
The content of graphite was 67% by weight, the content of ferrite was 13% by weight, and the content of phenol resin was 20% by weight. These were pulverized to a particle size of 105 μm or less and used.

(Example 1) In 2000 liters of water, 25 kg of ceramic fiber ("SC1260 bulk" manufactured by Nippon Steel Chemical Co., Ltd.) and 75 k of the self-curing particles of Production Example 1 were used.
g was blended to prepare a self-curing particle slurry 2 containing fibers. This self-curing particle slurry 2 was supplied to the papermaking vat 1 shown in FIG. 1, papermaking was performed by the papermaking drum 3, and the layer 7 of self-curing particles was transferred to the papermaking felt 4. After passing through a squeeze roll 9 for dehydration, the laminated layer 7 was peeled off from the papermaking felt 4 and dried with a dryer at 100 ° C. for 15 minutes to obtain a self-curable sheet 5.

The self-curable sheet 5 thus produced
Were laminated between stainless steel plates preheated to 160 ° C., and heated and pressed at a molding pressure of 100 kg / cm ² for 10 minutes to obtain a composite molded plate having a thickness of about 4 mm. (Example 2) A self-curing sheet was prepared in the same manner as in Example 1 except that the self-curing particles of Production Example 2 were used, and a composite molding having a thickness of about 4 mm was formed in the same manner as in Example 1. I got a board.

Example 3 A self-curable sheet was prepared in the same manner as in Example 1 except that the self-curable particles of Production Example 3 were used, and a thickness of about 4 m was obtained in the same manner as in Example 1.
m was obtained. (Example 4) A self-curable sheet was prepared in the same manner as in Example 1 except that the self-curable particles of Production Example 4 were used, and a composite molding having a thickness of about 4 mm was formed in the same manner as in Example 1. I got a board.

Comparative Example 1 The self-curing particles of Production Example 1 were
Place in a mold having a cavity with 150 mm × 130 mm vertical and horizontal dimensions, 160 ° C., 100 kg / cm
^{2. By} heating and pressing under the condition of 10 minutes,
A composite molded plate having a thickness of about 4 mm was obtained. The thickness, basis weight, density, tensile strength, and tear strength of the self-curable sheets prepared in Examples 1 to 4 were measured, and the paper formability was evaluated. Table 1 shows the results. Incidentally, the evaluation of the papermaking property, the uniformity of the thickness of the solid content adhered to the papermaking felt of the self-curable particle slurry, and the presence or absence of residual to the papermaking felt when peeled from the papermaking felt, by visual and vernier calipers Observation was carried out, and those having no problem were indicated by “◎”, and those having a residue on the papermaking felt were indicated by “○”.

[0049]

[Table 1]

As shown in Table 1, a self-curable sheet having a thickness of about 1 mm was produced by the papermaking method. The thickness and density of the composite molded plates obtained in Examples 1 to 4 and Comparative Example 1 were measured, and a fire resistance test was performed. Further, the electric resistivity was measured, and the electromagnetic wave shielding performance was measured. Table 2 shows the results.

In the fire resistance test, a composite molded plate having a size of 100 mm × 100 mm was used.
A high-temperature, high-speed flame having a flame length of 0 ° C and a flame length of 150 mm is vertically applied to the center of the surface of this composite molded plate held at a distance of 100 mm from the burner. This was done by determining the time required for the flame to evolve and penetrate.

The measurement of the electric resistivity is 50 mm × 50 mm
About the composite molded plate of the size of "Loresta AP (MCP-T400)" and "Hiresta IP" manufactured by Mitsubishi Yuka Co., Ltd.
(MCP-HT250) "using
The measurement was performed by determining the surface resistivity and the volume resistivity using an S probe. In addition, the composite molded plate has a temperature of 25 ± 2
The sample was left for 48 hours in a thermo-hygrostat at 50 ° C. and a relative humidity of 50 ± 5%, and then subjected to a test.

The measurement of the electromagnetic wave shielding performance is 150 mm
Using a composite molded plate having a size of × 70 mm as a specimen,
Dual Chamb compliant with ASTM ES-83
The measurement was performed by measuring the transmission loss of electromagnetic waves by the er method (proximal electric field).

[0054]

[Table 2]

It was confirmed that the fire resistance and the electromagnetic wave shielding properties of Examples 1 to 4 were equal to or superior to Comparative Example 1. Example 5 After dissolving 100 kg of polyvinyl alcohol ("PVA210" manufactured by Kuraray Co., Ltd.) in 2000 liters of water, 75 kg of the self-curing particles of Production Example 1 were blended, and a self-curing particle slurry containing a binder was added. 2 was prepared. Thereafter, the self-curing particle slurry 2 was used in Example 1
A self-curable sheet 5 was prepared in the same manner as in Example 1, and a composite molded plate having a thickness of about 4 mm was obtained using this self-curable sheet 5 in the same manner as in Example 1.

Example 6 After dissolving 100 kg of polyvinyl alcohol ("PVA210" manufactured by Kuraray Co., Ltd.) in 2000 liters of water, 25 kg of ceramic fiber ("SC1260 bulk" manufactured by Nippon Steel Chemical Co., Ltd.) was used. 75 kg of the self-curing particles were blended to prepare a self-curing particle slurry 2 containing a binder and fibers. Thereafter, the self-curable particle slurry is used to form a self-curable sheet 5 by using the self-curable particle slurry 2 in the same manner as in Example 1, and the thickness is about 4 mm in the same manner as in Example 1 using the self-curable sheet 5.
Was obtained.

The thickness, basis weight, density, tensile strength, and tear strength of the self-curable sheets prepared in Examples 5 to 6 were measured, and the paper formability was evaluated. Table 3 shows the results.

[0058]

[Table 3]

The composite molded plates obtained in Examples 5 to 6 were measured for thickness and density and subjected to a fire resistance test. Furthermore, the electrical resistivity and the electromagnetic wave shielding performance were measured. Table 4 shows the results.

[0060]

[Table 4]

(Example 7) In 2000 liters of water, 25 kg of ceramic fiber ("SC1260 bulk" manufactured by Nippon Steel Chemical Co., Ltd.) and 75 k of the self-curing particles of Production Example 1 were used.
g was blended to prepare a self-curing particle slurry 2. The self-curable particle slurry 2 was supplied to the papermaking vat 1 shown in FIG. 3, papermaking was performed by the papermaking drum 3, and the aggregated layer 7 of the self-curable particles was transferred to the papermaking felt 4. And squeeze roll 9
After the dehydration, 500 g of an acrylic emulsion liquid having a solid content of 10% by weight as the secondary binder 8 is formed on the laminated layer 7.
/ M was applied at a coating weight of ² to penetrate the assembled layer 1, then after dewatered excess emulsion solution through squeeze rolls 10, peeled off assembly layer 7 from the papermaking felt 4, 10
By drying with a dryer at 0 ° C. for 15 minutes, a self-curable sheet 5 was obtained. After that, using this self-curing sheet,
It was molded in the same manner as in Example 1 to obtain a composite molded plate having a thickness of about 4 mm.

(Example 8) A self-curing sheet was prepared in the same manner as in Example 7 except that the self-curing particles of Production Example 2 were used, and a composite molded plate having a thickness of about 4 mm was obtained. . (Example 9) A self-curing sheet was prepared in the same manner as in Example 7 except that the self-curing particles of Production Example 3 were used, and a composite molded plate having a thickness of about 4 mm was obtained.

(Example 10) A self-curing sheet was produced in the same manner as in Example 7, except that the self-curing particles of Production Example 4 were used, and a composite molded plate having a thickness of about 4 mm was obtained. . (Example 11) Example 5 was used as a self-curing particle slurry.
A self-curable sheet was prepared in the same manner as in Example 7, except that the self-curable particle slurry prepared in the above was used, and a composite molded plate having a thickness of about 4 mm was obtained.

(Example 12) A self-curing sheet was prepared in the same manner as in Example 7, except that the self-curing particle slurry prepared in Example 6 was used as the self-curing particle slurry. A composite molded plate having a thickness of about 4 mm was obtained. The thickness, basis weight, density, tensile strength, and tear strength of the self-curable sheets prepared in Examples 7 to 12 were measured. Table 5 shows the results.

[0065]

[Table 5]

The composite molded plates obtained in Examples 7 to 12 were measured for thickness and density and subjected to a fire resistance test. Furthermore, the electrical resistivity and the electromagnetic wave shielding performance were measured. Table 6 shows the results.

[0067]

[Table 6]

(Example 13) Self-curing particle slurry 2 was prepared by mixing 75 kg of the self-curing particles of Production Example 1 in 2000 liters of water, and ceramic fiber ("Nippon Steel Chemical Co., Ltd." SC1260 bulk ") was blended in an amount of 25 kg to prepare a fiber slurry 11. Then, the self-curing particle slurry 2 is supplied to the papermaking vat 1 of FIG. 4 and the fiber slurry 11 is supplied to the fiber slurry papermaking vat 12, and the fiber layer 14 formed by the fiber slurry papermaking drum 13 is transferred to the surface of the papermaking felt 4. At the same time, the assembling layer 7 of the self-curing particles formed by the papermaking drum 3 was transferred onto the fiber layer 14 on the surface of the papermaking felt 4. After passing through a squeeze roll 9 to dehydrate, the laminated layer 7 and the fiber layer 14 are peeled off from the papermaking felt 4, and
By drying in a dryer at 15 ° C. for 15 minutes.
And a self-curable sheet 5 comprising the fiber layer 14. After that,
Using this self-curable sheet, a composite molded plate having a thickness of about 4 mm was obtained in the same manner as in Example 1.

(Example 14) The same as Example 13 except that the fiber-containing self-curable particle slurry 2 prepared in Example 1 was used as the self-curable particle slurry 2 supplied to the papermaking vat 1. Thus, a self-curable sheet 5 composed of the laminated layer 7 and the fiber layer 14 was produced, and a composite molded plate having a thickness of about 4 mm was obtained.

(Example 15) The same as Example 13 except that the self-curing particle slurry 2 containing the binder prepared in Example 5 was used as the self-curing particle slurry 2 supplied to the papermaking vat 1. Laminated layer 7 and fiber layer 14
A self-curing sheet 5 made of
m was obtained.

Example 16 Example 13 was repeated except that the self-curing particle slurry 2 containing the fiber and binder prepared in Example 6 was used as the self-curing particle slurry 2 supplied to the papermaking vat 1. A self-curable sheet 5 composed of the laminated layer 7 and the fiber layer 14 was produced in the same manner as described above, and a composite molded plate having a thickness of about 4 mm was obtained.

(Example 17) In Example 13, the layer 7 and the fiber layer 14 of the self-curing particles transferred to the surface of the papermaking felt 4 were passed through a squeeze roll 9 to be dehydrated. Solid content 10% by weight as secondary binder 8
Is sprayed at an application amount of 500 g / m ² to permeate the laminated layer 7, and then the excess emulsion is removed through a squeeze roll 10 similar to that shown in FIG. Was peeled off from the papermaking felt 4 and dried with a dryer at 100 ° C. for 15 minutes to obtain a self-curable sheet 5 composed of the laminated layer 7 and the fiber layer 14. Thereafter, using this self-curing sheet, molding was performed in the same manner as in Example 1 to obtain a composite molded plate having a thickness of about 4 mm.

Example 18 In Example 14, the secondary binder 8 was allowed to permeate the laminated layer 7 in the same manner as in Example 17. Otherwise, a self-curing sheet 5 was prepared in the same manner as in Example 14, and a thickness of about 4
mm was obtained. (Example 19) In Example 15, as in Example 17, the secondary binder 8 was allowed to permeate the laminated layer 7. Other than that produced the self-hardening sheet | seat 5 like Example 14, and about 4 mm-thick composite molded board was obtained using this self-hardening sheet | seat.

(Example 20) In Example 16, as in Example 17, the secondary binder 8 was allowed to permeate the laminated layer 7. Otherwise, a self-curing sheet 5 was prepared in the same manner as in Example 14, and a thickness of about 4
mm was obtained. The thickness, basis weight, density, tensile strength, and tear strength of the self-curable sheets prepared in Examples 13 to 20 were measured, and the paper formability was evaluated. Table 7 shows the results.

[0075]

[Table 7]

The composite molded plates obtained in Examples 13 to 20 were measured for thickness and density and subjected to a fire resistance test. Furthermore, the electrical resistivity and the electromagnetic wave shielding performance were measured.
Table 8 shows the results.

[0077]

[Table 8]

Example 21 Ceramic fiber nonwoven fabric (E)
Rivest “FBP-030”: Basis weight 30 g / m ^Two)
Is used as the reinforcing sheet 15 and the felt 4 of FIG.
The reinforcing sheet 15 was supplied along the surface. FIG.
Self-curing with fiber prepared in Example 1 on papermaking vat 1
Is supplied to the slurry 2 and the papermaking drum 3
The laminated layer 7 of the curable particles is used for reinforcing the surface of the papermaking felt 4.
The transfer was performed on the sheet 15. This is squeeze roll 9
Reinforced sheet 15 to which laminated layer 7 adheres after dehydration through
Was peeled off from the papermaking felt 4 and dried in a dryer at 100 ° C. for 15 minutes.
After drying for 5 minutes, the laminated layer 7 and the reinforcing sheet 15
Was obtained. After that, this self-curing
Using the sheet 5, a thickness of about 4 mm
A composite molded plate was obtained.

(Example 22) The same as Example 21 except that the self-curing particle slurry 2 containing the binder prepared in Example 5 was used as the self-curing particle slurry 2 supplied to the papermaking vat 1. Thus, a self-curable sheet 5 composed of the laminated layer 7 and the reinforcing sheet 15 was produced, and a composite molded plate having a thickness of about 4 mm was obtained.

Example 23 The self-curing particle slurry 2 containing the fiber and the binder prepared in Example 6 was used as the self-curing particle slurry 2 to be supplied to the papermaking vat 1, except that the self-curing particle slurry 2 containing the fiber and the binder was used. A self-curable sheet 5 composed of the laminated layer 7 and the fiber layer 14 was produced in the same manner as described above, and a composite molded plate having a thickness of about 4 mm was obtained.

(Example 24) Ceramic fiber nonwoven fabric
Rivest “FBP-030”: Basis weight 30 g / m ^Two)
Is used as the reinforcing sheet 15 and the felt 4 of FIG.
The reinforcing sheet 15 was supplied along the surface. FIG.
Self-curing with fiber prepared in Example 1 on papermaking vat 1
Is supplied to the slurry 2 and the papermaking drum 3
The laminated layer 7 of the curable particles is used for reinforcing the surface of the papermaking felt 4.
The transfer was performed on the sheet 15. Next, on this layer 7
The reinforcing sheet 15 is supplied by the overlapping roll 19 to
After passing this through the squeeze roll 9 and dewatering,
In which laminated layer 7 is sandwiched between reinforcing sheets 15 of
Peeling material is removed from the felt 4 and dried at 100 ° C.
By drying for 15 minutes at
A self-curable sheet 5 composed of the strong sheet 15 was obtained. After that,
Using this self-curing sheet 5, the thickness is increased in the same manner as in Example 1.
A composite molded plate of about 4 mm was obtained.

(Example 25) In Example 24, the laminated layer 7 sandwiched by the two reinforcing sheets 15 was dewatered by passing through a squeeze roll 9 and then a secondary binder 8 having a solid content of 10% by weight was formed thereon. The acrylic emulsion was sprayed at a coating amount of 500 g / m ² to permeate the laminated layer 7, and then the excess emulsion was removed through a squeeze roll 10 similar to that shown in FIG.
The self-curing sheet 5 composed of the laminated layer 7 and the two reinforcing sheets 15 is removed by peeling the sheet material sandwiching the laminated layer 7 between the felts 5 from the papermaking felt 4 and drying the sheet material with a dryer at 100 ° C. for 15 minutes. Obtained. Thereafter, using this self-curable sheet 5, a composite molded plate having a thickness of about 4 mm was obtained in the same manner as in Example 1.

The thickness, basis weight, density, tensile strength, and tear strength of the self-curable sheets prepared in Examples 21 to 25 were measured. Table 9 shows the results.

[0084]

[Table 9]

Further, the composite molded plates obtained in Examples 21 to 25 were measured for thickness and density and subjected to a fire resistance test. Furthermore, the electrical resistivity and the electromagnetic wave shielding performance were measured.
Table 10 shows the results.

[0086]

[Table 10]

[0087]

As described above, according to the present invention, a self-curing particle slurry in which self-curing particles comprising fire-resistant and conductive powder and self-curing thermosetting resin are dispersed is prepared,
This self-curing particle slurry was formed into a self-curing sheet in which self-curing particles were aggregated, and the self-curing sheet was heated and pressed, so that the same method as that for paper and the like was used. It is possible to produce a self-curable sheet with a uniform thickness like paper, and any thickness from thin to thick, and to produce a self-curable sheet with high productivity. Further, by heating and pressurizing the self-curing sheet, it is possible to obtain a composite molded article having excellent fire resistance and electromagnetic wave shielding properties due to a powdery material having fire resistance and conductivity.

According to the second aspect of the present invention, the self-curing particles are obtained by mixing and reacting a resin raw material with a powdery material having fire resistance and conductivity. The particles can be uniformly dispersed in the thermosetting resin in the conductive particles, and a high electromagnetic wave shielding effect can be obtained by the uniform dispersion of the particles.

According to the third aspect of the present invention, since the self-curable particle slurry prepared by dispersing the self-curable particles and the fibers is used, the self-curable particles can be bound by entanglement of the fibers, A self-curable sheet having high strength can be produced. Further, since the invention of claim 4 uses a self-curing particle slurry prepared by dispersing the self-curing particles and the binder, the self-curing particles can be bonded by the adhesive action of the binder, and high strength can be obtained. Can be produced.

According to the fifth aspect of the present invention, a self-curing particle slurry prepared by dispersing self-curing particles, fibers and a binder is used. And a high-strength self-curable sheet can be produced. The invention according to claim 6 is characterized in that the self-curing particle slurry is filtered on the surface of a papermaking drum to form a paper and transferred to the surface of an infinite belt-like papermaking felt.
Since the self-curable sheet is produced, the self-curable sheet can be produced continuously with high productivity.

According to the seventh aspect of the present invention, the self-curable sheet is laminated on another base material and molded by heating and pressurizing. Therefore, the composite molded body of the self-curable sheet is laminated on the base material and used. And can be used for a wider range of applications. According to the invention of claim 8, since the secondary binder is made to penetrate into the self-curable sheet, the self-curable particles can be bonded by the adhesive action of the secondary binder, and the self-curable sheet having high strength can be obtained. What you can get.

According to the ninth aspect of the present invention, a fiber layer is formed by forming a fiber slurry on the surface of an infinite belt-shaped papermaking felt, and a laminated layer formed by forming a self-curing particle slurry is laminated on the surface of the fiber layer. By doing so, a self-curing sheet composed of a fiber layer and a laminated layer of self-curing particles is produced, so that the self-curing sheet can be reinforced by the fiber layer, and a high strength self-curing sheet is obtained. Is what you can do.

[0093] The invention of claim 10 provides a reinforcing sheet by stacking a reinforcing sheet on the surface of an infinite belt-shaped papermaking felt and laminating a laminated layer of self-curing particle slurry on the surface of the reinforcing sheet. And a self-curing sheet composed of a layer of self-curing particles, so that the self-curing sheet can be reinforced by a reinforcing sheet, and a high-strength self-curing sheet can be obtained. is there.

Further, the invention of claim 11 is characterized in that a laminated layer obtained by forming a self-curing particle slurry is laminated on the surface of the reinforcing sheet, and then the reinforcing sheet is laminated on the surface of the laminated layer to laminate two layers. Since the self-curing sheet in which the laminated layer of the self-curing particles is sandwiched by the reinforcing sheet is produced, the self-curing sheet can be reinforced by the reinforcing sheet, and a high-strength self-curing sheet can be obtained. You can do it.

[Brief description of the drawings]

FIG. 1 shows an example of an embodiment of the present invention,
(A) is a schematic diagram, (b) is an enlarged schematic diagram of a part of (a).

FIG. 2 is a front view showing an example of a composite molded body.

FIG. 3 shows another example of the embodiment of the present invention,
(A) is a schematic diagram, (b) is an enlarged schematic diagram of a part of (a).

FIG. 4 shows another example of the embodiment of the present invention,
(A) is a schematic diagram, (b) is an enlarged schematic diagram of a part of (a).

FIG. 5 shows another example of the embodiment of the present invention;
(A) is a schematic diagram, (b) is an enlarged schematic diagram of a part of (a).

FIG. 6 shows another example of the embodiment of the present invention,
(A) is a schematic diagram, (b) is an enlarged schematic diagram of a part of (a).

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 papermaking vat 2 self-curing particle slurry 3 papermaking drum 4 papermaking felt 5 self-curing sheet 6 base material 7 laminated layer 8 secondary binder 11 fiber slurry 12 fiber slurry papermaking bat 13 fiber slurry papermaking drum 14 fiber layer 15 reinforcing sheet

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI D21H 27/00 D21H 5/00 EG

Claims (11)

[Claims] 1. A self-curing particle slurry is prepared by dispersing self-curing particles comprising a fire-resistant and conductive powder and a self-curing thermosetting resin, and forming the self-curing particle slurry. Producing a self-curing sheet in which self-curing particles are assembled, and subjecting the self-curing sheet to heat and pressure molding. 2. The composite molding according to claim 1, wherein the self-curing particles are obtained by mixing and reacting a resin raw material with a powdery material having fire resistance and conductivity. How to make the body. 3. The method for producing a composite molded article according to claim 1, wherein a self-curing particle slurry prepared by dispersing self-curing particles and fibers is used. 4. The method according to claim 1, wherein a self-curing particle slurry prepared by dispersing self-curing particles and a binder is used. 5. The method for producing a composite molded article according to claim 1, wherein a self-curing particle slurry prepared by dispersing self-curing particles, fibers, and a binder is used. 6. A self-curing sheet is produced by filtering the self-curing particle slurry on the surface of a papermaking drum, forming the self-curing particle slurry, and transferring the slurry to the surface of an infinite belt-shaped papermaking felt. 6. The method for producing a composite molded article according to any one of claims 1 to 5. 7. The method for producing a composite molded article according to claim 1, wherein the self-curing sheet is laminated on another substrate and molded by heating and pressing. 8. The method for producing a composite molded article according to claim 1, wherein a secondary binder is impregnated in the self-curable sheet. 9. A fiber layer is formed by forming a fiber slurry on the surface of an infinite belt-shaped papermaking felt, and a laminated layer formed by forming a self-curing particle slurry is laminated on the surface of the fiber layer. 9. A self-curing sheet comprising a layer of self-curing particles is produced.
The method for producing a composite molded article according to any one of the above. 10. A reinforcing sheet is laminated on a surface of an infinite belt-shaped papermaking felt and fed, and a laminated layer obtained by forming a self-curing particle slurry on the surface of the reinforcing sheet is laminated. The method for producing a composite molded article according to any one of claims 1 to 8, wherein a self-curable sheet including a laminated layer is produced. 11. A laminated layer obtained by forming a self-curing particle slurry on the surface of a reinforcing sheet is laminated, and then a reinforcing sheet is laminated on the surface of the laminated layer to laminate the two layers. The method for producing a composite molded article according to claim 10, wherein a self-curable sheet in which an aggregate layer of particles is sandwiched is produced.